Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods

ABSTRACT

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 15/816,983, filed on Nov. 17, 2017 and titled MATTRESSES INCLUDING AN ELASTOMERIC CUSHIONING ELEMENT AND A POCKETED COIL LAYER AND RELATED METHODS (“the '983 application”). The entire disclosure of the '983 application is hereby incorporated herein.

FIELD

Embodiments of the disclosure relate generally to cushioning elements such as mattresses including a pocketed coil layer, and to methods of making such mattresses.

BACKGROUND

Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and/or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. Cushioning materials may be used in combination with one another to achieve selected properties. For example, mattresses may include pocketed coils in combination with layers of foam, elastomer gels, etc., in order to achieve desired results in the cushioning materials.

In mattresses, springs (e.g., coil springs) may be preferable to foam for their durability and ability to withstand compression. Springs may also impart a feel that may be more desirable to users than that of foam. Despite these advantages, springs may not provide a positive aesthetic and/or tactile experience if they are seen or felt through side panels of the mattress, prompting manufacturers to conceal the feel of springs on the sides of mattresses. One solution includes a wire frame around the edge of the mattress to provide structure to a cover of the mattress. However, the metal of the wire frame may be felt through the cover of the mattress. In addition, such a wire frame may not be particularly suited to handle compression during use and to packing mattresses for shipping and/or storage, such as direct-to-consumer mattresses that are shipped in logs, boxes, etc.

SUMMARY

In some embodiments, a mattress assembly may include a base layer, a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer, wherein the elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.

In other embodiments, a mattress assembly may include a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and at least one elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils, and each pocketed coil of the plurality of pocketed coils may include a plurality of casings and a coil disposed within the plurality of casings. The at least one elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches.

In further embodiments, a method of forming a mattress assembly may include disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, wherein a thickness of the elastomeric cushioning element comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly, and disposing an outer covering over at least the upper layer.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a mattress assembly according to the present disclosure;

FIG. 2 is a simplified perspective view of the mattress assembly of FIG. 1;

FIG. 3 is a perspective view of an elastomeric cushioning element according to one or more embodiments of the present disclosure;

FIG. 4 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;

FIG. 5 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;

FIG. 6 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;

FIG. 7 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;

FIG. 8 is a top schematic view of a mattress assembly according to one or more embodiments of the present disclosure;

FIG. 9 is a top schematic view of a mattress assembly according to one or more embodiments of the present disclosure; and

FIG. 10 is a flowchart of a method of forming a mattress assembly according to one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

The following description provides specific details, such as material types, manufacturing processes, uses, and structures in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the disclosure. However, other embodiments may be utilized, and structural, procedural, and other changes may be made without departing from the scope of the disclosure. The illustrations presented herein are not meant to be actual views of any particular system, device, structure, or process, but are idealized representations that are employed to describe the embodiments of the disclosure. The drawings presented herein are not necessarily drawn to scale. Similar structures or components in the various drawings may retain the same or similar numbering for the convenience of the reader; however, the similarity in numbering does not mean that the structures or components are necessarily identical in size, composition, configuration, or other property.

As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” “upper,” “base,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress when oriented for sleeping in a conventional manner. Furthermore, these terms may refer to an orientation of elements of a mattress assembly as illustrated in the drawings.

As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, or even at least about 99% met.

As used herein, the term “elastomeric polymer” means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).

As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).

As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Plasticizers include, without limitation, hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.

As used herein, the term “elastomeric material” means and includes elastomeric polymers and mixtures of elastomeric polymers with plasticizers and/or other materials. Elastomeric materials are elastic (i.e., capable of recovering size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as “elastomer gels,” “gelatinous elastomers,” or simply “gels.”

Embodiments of the present disclosure include a mattress assembly having an elastomeric cushioning element that comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. For example, the elastomeric cushioning element may comprise about 30.8% of the overall thickness of the mattress assembly.

Additional embodiments of the present disclosure include a mattress assembly having a coil layer that includes a plurality of coils with each coil of the plurality of coils being disposed in multiple casings (e.g., bags). For example, each coil may be disposed within two or more polypropylene bags.

Further embodiments of the present disclosure include a mattress assembly having a latex water based adhesive disposed between one or more layers of the mattress assembly.

FIG. 1 shows a mattress assembly 100 according to one or more embodiments of the present disclosure. FIG. 2 shows a simplified top perspective view of the mattress assembly 100 of FIG. 1. In FIG. 2, various portions of the mattress assembly 100 are removed to provide a cutaway view and to better show internal components of the mattress assembly 100. Referring to FIGS. 1 and 2 together, in one or more embodiments, the mattress assembly 100 may include a base layer 102, a coil layer 104, an upper layer 106, an elastomeric cushioning element 108, an edge portion 119, one or more side panels 114, and the outer covering 112.

The base layer 102 may have generally planar top and bottom surfaces. The coil layer 104 may be disposed on the top surface of the base layer 102 and between the base layer 102 and the upper layer 106. In particular, the upper layer 106 may be disposed over and may at least substantially extend over the coil layer 104. The elastomeric cushioning element 108 may be disposed over an upper surface of the upper layer 106 and may extend over at least a portion of the upper layer 106. The edge portion 119 may extend around an outer peripheral edge of the elastomeric cushioning element 108. The one or more side panels 114 may extend along outer perimeters of the base layer 102 and the upper layer 106 and may be disposed between the upper layer 106 and the base layer 102. Furthermore, the one or more side panels 114 may extend within a plane perpendicular to a plane defined by the top surface of the base layer 102. The outer covering 112 may extend from the base layer 102 and may at least substantially encase the coil layer 104, upper layer 106, and elastomeric cushioning element 108.

In some embodiments, the mattress assembly 100 may include a stabilization material 116 between the elastomeric cushioning element 108 and the upper layer 106. In some instances, the stabilization material 116 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushioning element 108 to surrounding materials, such as another elastomeric cushioning element 108 and/or an upper surface of the upper layer 106. In some embodiments, the stabilization material 116 may comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element 108 may seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of the stabilization material 116. For example, when the elastomeric cushioning element 108 includes a gel material (as described below), portions of the gel material may be heat fused through the stabilization material 116. The portions of the elastomeric cushioning element 108 that extend through the scrim fabric of the stabilization material 116 may create a non-slip surface or reduced slip surface on a lower surface of the stabilization material 116 (e.g., surface that would contact an upper surface of the upper layer 106). The non-slip surface or reduced slip surface created by the elastomeric cushioning element 108 may help the cushioning materials stay in place relative to one another.

Furthermore, in some embodiments, an adhesive may be disposed between the stabilization material 116 and the upper surface of the upper layer 106. However, an adhesive may not be disposed between the edge portion 119 and the upper layer 106. Furthermore, an adhesive may be disposed between the base layer 102 and the coil layer 104. Moreover, an adhesive may be disposed between the coil layer 104 and the upper layer 106. Additionally, an adhesive may be disposed between the one or more side panels 114 and the coil layer 104. In some embodiments the adhesive(s) may include a latex water based adhesive. For instance, in one or more embodiments, the adhesive(s) may include one or more of SIMALFA® 338 and SIMALFA® 310.

In one or more embodiments, the mattress assembly 100 may not include a stabilization material 116 between the coil layer 104 and the upper layer 106 of the mattress assembly 100. However, in some instances, an adhesive may be disposed between the stabilization material 116 and the upper surface of the upper layer 106. For example, the adhesive may include any of the adhesives described above.

In some embodiments, the outer covering 112 may comprise a stretchable material that may be secured to or be integral with the elastomeric cushioning element 108. Such a stretchable material is described in U.S. patent application Ser. No. 15/062,621, to Pearce, filed Mar. 7, 2016, the entire disclosure of which is incorporated herein by this reference.

In one or more embodiments, the base layer 102 and the upper layer 106 may include a polyurethane foam. In additional embodiments, the base layer 102 and the upper layer 106 may include one or more of a memory polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, the base layer 102 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³ and an indention load deflection (ILD) of 55 (i.e., 55 ILD). Additionally, the upper layer 106 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³ and 18 ILD. The one or more side panels 114 may also include a polyurethane foam or any other spacer fabric known in the art. For example, the one or more side panels 114 may include any of the side panels described in U.S. patent application Ser. No. 15/662,934, to Moon et al., filed Jul. 28, 2017, the disclosure of which is incorporated in its entirety by this reference herein.

The coil layer 104 may include a plurality of coils 118 (e.g., steel coils), and each coil 118 of the plurality of coils 118 may be encased in at least one respective casing 120 (e.g., polypropylene socks or bags). For example, each casing 120 may form a pocket for a respective coil 118. In other words, the plurality of coils 118 may include a plurality of pocketed coils 118. In some embodiments, each coil 118 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Furthermore, in one or more embodiments, each coil 118 may be encased in multiple casings 120. For instance, each coil 118 may be double bagged or triple bagged. In one or more embodiments, the casings 120 may include a polypropylene material.

The casings 120 may include a two-ply polypropylene non-woven material. In one or more embodiments, the polypropylene non-woven material may include one or more of BERRY® products 1430408, 1430379, and 1430538. In some embodiments, each ply of the casings 120 may have a thickness within a range of about 0.10 mm and about 0.40 mm. As a non-limiting example, each ply of the casings 120 may have a thickness within a range of about 0.15 mm and about 0.30 mm. However, any suitable material may be used. The casings 120 may provide sound dampening effects.

For example, the mattress assembly 100 was tested according to a test method of utilizing the application SOUND METER by Abc Apps from the Google Play Store on a Galaxy S6 Active phone to measure sound levels from the mattress assembly 100. During the test method, a 3×3 coil structure having each coil 118 covered by the above-described casings 120 was compressed multiple times for the duration of 15 seconds, and the 3×3 coil structure exhibited an average sound level within a range of about 35 decibels and about 45 decibels. For example, the 3×3 coil structure exhibited an average sound level of about 40 decibels. In comparison, conventional mattresses, when tested according to the above test method, exhibited an average sound level of about 50 decibels. Accordingly, by encasing each coil 118 with multiple casings 120 (e.g., a first casing 120 and a second casing 120), the mattress assembly 200 of the present disclosure may be advantageous over conventional mattress assemblies. For example, the mattress assembly 100 may be quieter than conventional mattresses (e.g., may exhibit about 20% less sound than conventional mattresses).

In some embodiments, each casing 120 of each coil 118 of the plurality of coils 118 may be individual and discrete. In additional embodiments, the casings 120 of the plurality of coils 118 may be connected (i.e., joined) and may form a single body. Furthermore, each coil 118 of the plurality of coils 118 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 102. Furthermore, the plurality of coils 118 may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 104.

FIG. 3 a simplified perspective view of the elastomeric cushioning element 108. The elastomeric cushioning element 108 may include a singly-molded elastomeric cushioning element 108. For example, the entirety of the elastomeric cushioning element 108 may be formed via a single molding process. In some embodiments, the elastomeric cushioning element 108 may include buckling walls 122. The buckling walls 122 of the elastomeric cushioning element 108 may be interconnected to one another and may define hollow columns 124 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which a elastomeric cushioning element 108 has its original size and shape and wherein the buckling walls 122 are separated and define hollow columns 124.

The buckling walls 122 may extend in two directions, intersecting at right angles, and defining square voids 126. However, in some embodiments, the buckling walls 122 may intersect at other angles and define voids 126 of other shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning element 108 may comprise additional structures and configurations such as those structures and configurations described in, for example, U.S. Pat. No. 8,434,748, titled “Cushions Comprising Gel Springs,” issued May 7, 2013; U.S. Pat. No. 8,628,067, titled “Cushions Comprising Core Structures and Related Methods,” issued Jan. 14, 2014; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014; and U.S. Pat. No. 8,932,692, titled “Cushions Comprising Deformable Members and Related Methods,” issued Jan. 13, 2015, the entire disclosure of each of which is incorporated herein by this reference.

The buckling walls 122 may be formed of an elastomeric material. Elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999 (hereinafter “the '450 patent”); U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, titled “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014 (hereinafter “the '750 patent”); the disclosures of each of which are incorporated herein in their entirety by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.

The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.

The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®.

In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about 0.1:1 to about 50:1 by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about 4:1 by weight.

The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about 20° C. to about 45° C.

The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, N.J. or as EVERNOX®-10, from Everspring Corp. USA, of Los Angeles, Calif.; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of the '450 patent. The elastomeric material may include up to about 5 wt % antioxidants. For instance, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.

In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of the elastomeric cushioning element 108 after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, Tenn., under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.

In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide the elastomeric cushioning element 108 with an appearance appealing to consumers. In addition, an elastomeric cushioning element 108 having a dark color may absorb radiation differently than an elastomeric cushioning element 108 having a light color.

The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.

The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.

Referring again to FIG. 2 again, a configuration of having the coil layer 104 with the upper layer 106 on top of the coil layer 104 and the elastomeric cushioning element 108 on top of the upper layer 106 may provide advantages over conventional mattress assemblies. For example, in comparison to conventional mattress assemblies, the plurality of coils 118 of the coil layer 104 may better conform to an upper surface of the mattress assembly 100. For instance, when subjected to a weight (e.g., a person on the mattress assembly 100) and a resulting deformation, the plurality of coils 118 of the coil layer 104 may better conform to the deformation. Furthermore, the configuration may provide an increase in lateral stability in comparison to conventional mattress assemblies. Additionally, the foregoing configuration may make methods of manufacturing the mattress assembly 100 easier in comparison to conventional methods of manufacturing mattresses because it removes a need to laminate/glue the coil layer 104 to the elastomeric cushioning element 108. Having the upper layer 106 between the coil layer 104 and the elastomeric cushioning element 108 provides a porous surface to adhere to both of the coil layer 104 and the elastomeric cushioning element 108. Furthermore, the upper layer 106 dampens sound from the coil layer 104.

FIGS. 4-7 show schematic side cross-sectional views of mattress assemblies according to embodiments of the present disclosure. As shown in FIG. 4, in some embodiments, the elastomeric cushioning element 108 may not cover an entirety of an upper surface of the upper layer 106 of the mattress assembly 100. In such embodiments, the mattress assembly 100 may further include one or more segments 128 of foam (e.g., a polyurethane foam) in place of the elastomeric cushioning element 108 to provide an at least substantially planar upper surface of the mattress assembly 100. For instance, the one or more segments 128 of foam may be disposed adjacent to the elastomeric cushioning element 108 on the upper layer 106 of the mattress assembly 100.

In some embodiments, the elastomeric cushioning element 108 may be disposed only over a center portion of the upper layer 106 of the mattress assembly 100. For example, the elastomeric cushioning element 108 may not cover a portion of the upper layer 106 extending around a perimeter of the upper layer 106 of the mattress assembly 100. In such embodiments, the segments of foam 128 may be disposed over the portion of the upper layer 106 extending around a perimeter of the upper layer 106. The foregoing configuration may be utilized with mattress sizes where only one sleeper is expected (i.e., twin and full sized mattress).

In additional embodiments, the elastomeric cushioning element 108 may be disposed only in areas anticipated as predominant sleeping areas of sleepers. For example, the elastomeric cushioning element 108 may include two separate sections centered on opposing longitudinal halves of the mattress assembly 100. The foregoing configuration may be utilized with mattress sizes where two sleepers are expected (i.e., king, queen, and full sized mattresses). Furthermore, the foregoing embodiment is described in further detail with reference to FIG. 8.

As show in FIGS. 5-7, a thickness of the elastomeric cushioning element 108 may vary. In some embodiments, the elastomeric cushioning element 108 may have a thickness T of within a range of about 1.5 inches to about 2.5 inches. Furthermore, in some instances, the thickness T of the elastomeric cushioning element 108 may comprise between about 15.0% and about 20.0% of an overall thickness of the mattress assembly 100. For instance, the elastomeric cushioning element 108 may have a thickness T of about 2.0 inches and a thickness T that comprises about 18.2% of the overall thickness of the mattress assembly 100. In additional embodiments, the elastomeric cushioning element 108 may have a thickness T of within a range of about 2.5 inches to about 3.5 inches. Moreover, in some embodiments, the thickness T of the elastomeric cushioning element 108 may comprise between about 20.0% and about 30.0% of an overall thickness of the mattress assembly 100. For example, the elastomeric cushioning element 108 may have a thickness T of about 3.0 inches and a thickness T that comprises about 25.0% of the overall thickness of the mattress assembly 100. In further embodiments, the elastomeric cushioning element 108 may have a thickness T of within a range of about 3.5 inches to about 4.5 inches. Additionally, in one or more embodiments, the thickness T of the elastomeric cushioning element 108 may comprise between about 30.0% and about 35.0% of an overall thickness of the mattress assembly 100. As a non-limiting example, the elastomeric cushioning element 108 may have a thickness T of about 4.0 inches and a thickness T that comprises about 30.8% of the overall thickness of the mattress assembly 100.

Referring still to FIGS. 5-7, in some embodiments, the upper layer 106 of the mattress assembly 100 may have a thickness within a range of about 0.25 inch and about 0.75 inch. For instance, the upper layer 106 of the mattress assembly 100 may have a thickness of about 0.50 inch. Additionally, the coil layer 104 of the mattress assembly 100 may have a thickness (e.g., height) within range of about 6.0 inches and about 9.0 inches. For example, the coil layer 104 of the mattress assembly 100 may have a thickness of about 7.5 inches. Moreover, the base layer 102 of the mattress assembly 100 may a thickness within a range of about 0.50 inch and about 1.50 inches. As a non-limiting example, the base layer 102 may have a thickness of about 1.00 inch.

FIGS. 8 and 9 show top views of mattress assemblies according to embodiments of the present disclosure. As shown in FIG. 8, in some embodiments, the mattress assembly 800 may include one or more elastomeric cushioning element sections 802, 804 (e.g., a plurality of distinct elastomeric cushioning elements). Furthermore, the one or more elastomeric cushioning element sections 802, 804 may be disposed (e.g., located) in anticipated sleeping areas of one or more sleepers. For example, for a mattress size where two sleepers are anticipated (e.g., a queen and/or king size bed), the mattress assembly 800 may include a first elastomeric cushioning element section 802 and a second elastomeric cushioning element section 804. The first elastomeric cushioning element section 802 may be centered longitudinally within a first half 806 of the overall mattress assembly 800 (divided longitudinally), and the second elastomeric cushioning element section 804 may be centered longitudinally within a second half 808 of the overall mattress assembly 800. In some embodiments, each of the first elastomeric cushioning element section 802 and the second elastomeric cushioning element section 804 may have a width within a range of about 22.0 inches to about 28.0 inches. For instance, each of the first and second elastomeric cushioning element sections 802, 804 may have a width of about 25.0 inches. Furthermore, each of the first and second elastomeric cushioning element sections 802, 804 may have a length (e.g., longitudinal length) within a range of about 50.0 inches to about 65 inches. For example, the first and second elastomeric cushioning element sections 802, 804 may have a length of about 56.0 inches. Furthermore, a polyurethane foam 810 may be disposed where coverage is not provided by the first and second elastomeric cushioning element sections 802, 804. In some instances, the polyurethane foam 810 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³ and 18 ILD.

As shown in FIG. 9, in some embodiments, the elastomeric cushioning element 902 may provide complete coverage over a mattress assembly 900. For example, the elastomeric cushioning element 902 may cover at least substantially an entire upper surface of the upper layer 106 (FIG. 2) of the mattress assembly 900.

FIG. 10 shows a schematic flowchart of a method 1000 of forming a mattress assembly 100. In some embodiments, the method 1010 may include an act 1000 of disposing a coil layer 104 over a base layer 102. For example, act 1010 may include disposing a plurality of coils 118 within a plurality of casings 120, wherein each coil 118 of the plurality of coils 118 is disposed within at least two respective casings 120, and disposing the plurality of coils 118 over the coil layer 104. Additionally, act 1010 can include disposing the plurality of coils 118 within polypropylene bags. Furthermore, act 1010 may include orienting the plurality of coils 118 within an array (e.g., rows and columns) over the base layer 102. Moreover, act 1010 may include disposing the coil layer 104 over the base layer 102 according to any of the configurations described above in regard to FIGS. 1, 2, and 4-7.

Additionally, the method 1000 may include an act 1020 of disposing an upper layer 106 over the coil layer 104. In some embodiments, act 1020 may not include disposing a stabilization material between the coil layer 104 and the upper layer 106. However, in some embodiments, act 1020 may include disposing an adhesive between the coil layer 104 and the upper layer 106. For example, act 1020 may include disposing any of the adhesives described above between the coil layer 104 and the upper layer 106. Furthermore, act 1020 may include disposing an upper layer 106 over the coil layer 104 according to any of the configurations described above in regard to FIGS. 1, 2, and 4-7.

Moreover, the method 1000 may include an act 1030 of disposing an elastomeric cushioning element 108 over the upper layer 106. For example, act 1030 can include disposing an elastomeric cushioning element 108 over the upper layer 106 that comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly 100. For instance, a thickness of the elastomeric cushioning element 108 comprises between about 20.0% and about 32.0% of an overall thickness of the mattress assembly 100. In additional embodiments, act 1030 can include disposing an elastomeric cushioning element 108 over the upper layer 106 that comprises between about 25.0% and about 32.0% of an overall thickness of the mattress assembly 100. In further embodiments, act 1030 can include disposing an elastomeric cushioning element 108 over the upper layer 106 that comprises between about 30.0% and about 32.0% of an overall thickness of the mattress assembly 100. For instance, act 1030 can include disposing an elastomeric cushioning element 108 over the upper layer 106 that comprises about 30.8% of an overall thickness of the mattress assembly 100.

In some embodiments, act 1030 can include disposing a plurality of elastomeric cushioning element 108 segments over the upper layer 106. Moreover, act 1030 can include disposing an elastomeric cushioning element 108 over the upper layer 106 according to any of the configurations described above and including any of the materials described in regard to FIGS. 1-9.

Additionally, the method 1000 may include act 1040 of disposing an outer covering 112 over at least the upper layer 106. For example, act 1040 can include disposing an outer covering 112 over the mattress assembly 100 such that the outer covering 112 covers at least substantially an entirety of the upper layer 106 and side panels 114 of the mattress assembly 100. In one or more embodiments, the method 600 can include disposing an adhesive between any of the layers of the mattress assembly 100.

Additional non-limiting example embodiments of the disclosure are described below.

Embodiment 1: A mattress assembly, comprising: a base layer; a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coil; an upper layer disposed over the coil layer; and an elastomeric cushioning element disposed over the upper layer, wherein the elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.

Embodiment 2: The mattress assembly of Embodiment 1, wherein the coil layer has a thickness within a range of about 6.00 inches and about 8.00 inches.

Embodiment 3: The mattress assembly of Embodiment 2, wherein the coil layer has a thickness of about 7.50 inches.

Embodiment 4: The mattress assembly of Embodiment 1, further comprising: one or more side panels extending around outer perimeters of the base layer and the upper layer; and an outer covering disposed over the upper layer at least partially around the one or more side panels.

Embodiment 5: The mattress assembly of Embodiment 1, wherein the base layer and the upper layer both comprise a polyurethane foam.

Embodiment 6: The mattress assembly of Embodiment 1, wherein the elastomeric cushioning element has a thickness of about 4.0 inches.

Embodiment 7: The mattress assembly of Embodiment 1, further comprising an adhesive disposed between the elastomeric cushioning element and the upper layer.

Embodiment 8: The mattress assembly of Embodiment 7, wherein the adhesive comprises a latex water based adhesive.

Embodiment 9: The mattress assembly of Embodiment 1, wherein the base layer has a thickness within a range of about 0.75 inch and about 1.50 inches, and wherein the upper layer has a thickness within a range of about 0.25 inch and about 0.75 inch.

Embodiment 10: A mattress assembly, comprising: a base layer; a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, each pocketed coil of the plurality of pocketed coils comprises: a plurality of casings; and a coil disposed within the plurality of casings; an upper layer disposed over the coil layer; and at least one elastomeric cushioning element disposed over the upper layer, wherein the at least one elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.

Embodiment 11: The mattress assembly of Embodiment 10, wherein the plurality of pocketed coils is oriented next to each other in a grid pattern.

Embodiment 12: The mattress assembly of Embodiment 10, wherein the plurality of casings of each pocketed coil comprises: a first casing; and a second casing disposed within the first casing, wherein the coil is disposed within the second casing.

Embodiment 13: The mattress assembly of Embodiment 10, wherein the at least one elastomeric cushioning element comprises a plurality of distinct elastomeric cushioning elements disposed at different locations over the upper layer.

Embodiment 14: The mattress assembly of Embodiment 10, wherein the at least one elastomeric cushioning element does not cover an entirety of an upper surface of the upper layer.

Embodiment 15: The mattress assembly of Embodiment 11, wherein the at least one elastomeric cushioning element comprises interconnected buckling walls.

Embodiment 16: A method of forming a mattress assembly, comprising: disposing a coil layer over a base layer; disposing an upper layer over the coil layer; disposing an elastomeric cushioning element over the upper layer, wherein a thickness of the elastomeric cushioning element comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly; and disposing an outer covering over at least the upper layer.

Embodiment 17: The method of Embodiment 16, wherein disposing a coil layer over a base core layer comprises: disposing a plurality of coils within a plurality of casings, wherein each coil of the plurality of coils is disposed within at least two respective casings; and disposing the plurality of coils over the coil layer.

Embodiment 18: The method of Embodiment 17, wherein disposing a plurality of coils within a plurality of casings comprises disposing the plurality of coils within polypropylene bags.

Embodiment 19: The method of Embodiment 16, wherein the elastomeric cushioning element comprises about 30.8% of the overall thickness of the mattress assembly.

Embodiment 20: The method of Embodiment 16, further comprising disposing an adhesive between the elastomeric cushioning element and the upper layer.

While the present disclosure has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the disclosure as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the disclosure as contemplated. Further, embodiments of the disclosure have utility with different and various mattress types and configurations. 

What is claimed:
 1. A mattress, comprising: a first layer comprising a plurality of coils; a second layer over at least a portion of the first layer, the second layer comprising a foam; an elastomeric cushioning element over at least a portion of the second layer and adhered to the second layer.
 2. The mattress of claim 1, wherein: the plurality of coils comprises a plurality of individually wrapped coils.
 3. The mattress of claim 1, further comprising: an outer covering encasing the first layer, the second layer, and the elastomeric cushioning element.
 4. The mattress of claim 1, further comprising: one or more side panels extending around outer perimeters of the first layer and the second layer.
 5. The mattress of claim 4, further comprising: an outer covering encasing the first layer, the one or more side panels, the second layer, and the elastomeric cushioning element.
 6. The mattress of claim 1, wherein the second layer comprises a polyurethane foam.
 7. The mattress of claim 1, wherein the elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns.
 8. A mattress, comprising: a coil layer comprising an array of coils; a foam layer over the coil layer, the foam layer including a lower surface oriented toward the coil layer and an upper surface oriented away from the coil layer; an elastomer layer over the upper layer, the elastomer layer including a lower surface oriented toward the foam layer and an upper surface oriented away from the foam layer, the lower surface of the elastomer layer adhered to the foam layer.
 9. The mattress of claim 8, wherein the array of coils comprises individually wrapped coils.
 10. The mattress of claim 9, wherein each coil of the array of coils is disposed within a first polypropylene bag and the first polypropylene bag is disposed within a second polypropylene bag.
 11. The mattress of claim 10, further comprising: a base layer beneath the coil layer.
 12. The mattress of claim 11, further comprising: at least one side panel surrounding an outer periphery of the coil layer.
 13. The mattress of claim 12, wherein the base layer, the at least one side panel, and the foam layer encase the coil layer, dampening sound from the coil layer.
 14. The mattress of claim 13, further comprising: a cover over the base layer, the coil layer, the foam layer, the at least one side panel, and the elastomer layer.
 15. The mattress of claim 14, having a maximum sound level of about 45 decibels.
 16. The mattress of claim 14, having a maximum sound level of about 40 decibels.
 17. The mattress of claim 8, wherein the foam layer has a thickness of about 0.5 inch to about 1 inch.
 18. The mattress of claim 8, wherein the upper surface of the foam layer is porous to enable the elastomer layer to adhere to the upper surface of the foam layer.
 19. The mattress of claim 18, wherein the elastomer layer includes a scrim fabric at lower surface.
 20. The mattress of claim 19, wherein an elastomeric material of the elastomer layer secures the scrim fabric in place at the lower surface.
 21. The mattress of claim 20, wherein the scrim fabric enables the elastomer layer to adhere to the upper surface of the foam layer.
 22. The mattress of claim 18, wherein the lower surface of the foam layer is porous to enable the foam layer to adhere to the coil layer.
 23. The mattress of claim 8, wherein the elastomer layer is superimposed with a central location of the foam layer but not with peripheral portions of the foam layer. 